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A ProtoType Foundry
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Jonathan Harker 0808005
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A ProtoType Foundry Jonathan Harker A Technical Requisite
TABLE OF CONTENTS
INTRODUCTION A Systematic Approach
4
Birmingham: CIty of a Thousand Trades, Workshop to the World
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TECTONIC CONCEPT AND LANGUAGE Tectonic Concept
6
Robustness
7
The Typographic Kit of Parts
8
Materiality Precedents
10
Casting Concept
11
Materials Board
13
PROCESS Tectonic Process Storyboard
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Panel Ties and Stitching
18
Couplers and Rebar
21
Specifying Concrete
22
Curing
23
Event Application
24
Legacy Alteration
25
DETAILING Working from Tilt-Up Slab Principles
26
Foundations
27
Tying back into In-situ Spanning Slab Integrated Lighting
28
Roofing and Parapet
29
Difficulties in Site Specific Construction
30
PERFORMANCE
3
Generating U-Value
31
Ventilation Strategy
32
Fire Strategy
34
Heating and Cooling
36
Economic Proforma
37
A SYSTEMATIC APPROACH
This thesis shall consider the design of a systematic approach to pre-fabricated component construction that can be adopted as a commercial means of exhibiting. The nature of the spectacle of the understood ‘fair’ shall be appraised by plugging this architectural prototype EXPO model into former process driven industrial quarters. This is done whilst valuing that a constant presence in the architecture of exhibition design is the commercial drive to identify with products and processes through the treatment of built surface.
Permanence
[+]
[EXPO 2026?]
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A ProtoType Foundry Jonathan Harker A Technical Requisite
BIRMINGHAM: CITY OF A THOUSAND TRADES, WORKSHOP TO THE WORLD.
Digbeth is an intensely industrial
The Duddeston viaduct is a
region of Birmingham and was chosen as a
blue brick elevated structure built in the
model urban situation for a manufacturing
mid 19th century with the intention of
focused reappraisal of the exhibition model.
linking the Great Western Rail line from
A site in central Digbeth mediates frequent
Oxford into Birmingham Moor Street
footfall between the proposed Curzon Street
with the London line from the time (of
high-speed rail terminal and planned
which the final stages form the route for
national scale sport facilities adjacent to
the new HS2 line. The opening of Snow
Birmingham City.
Hill station midway through construction however deemed this infrastructure link
Although characteristically defined
unrequired and it stands today with its
by the industrial architectural typologies,
fragmented terminus dotted across the
elevated rail infrastructure and arterial canal
meeting of the grand union canal and
system through the area, there is anonymity
the carved out junctions of industrial
about the processes and nature of the
Digbeth. This structure stands today as
industry that lies behind the Eastside of this
a monument to the modesty of the brick
trade city. These are broader traits of very
as a modular building component which
similar industrial urban fabrics, which have
shaped the masonry industrial fabric
also given birth to social bodies and
across the area.
entertainment venues further north along the second phase of high speed rail plans.
5
Tectonic Strateg
Masonry construstion with large spanning steel trusses
TECTONIC CONCEPT
Symmetrical or north light oriented industrial pitched roof typology Surface as sheild. Covert to programme
ONE ESTABLISHED MODULAR TYPOLOGY THAT SERVES AND FABRICATES ANOTHER
The typical industrial warehouse
or ‘shed’ typology consists of modular masonry construction with a steel column, beam and truss system supporting a corrugated metal roof usually with north light glazing. Tectonic Strategy
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ion with large spanning
Tectonic Strategy
rth light oriented industrial ogy
Covert to programme
This thesis aims to propose a
new modular prototype system of Tilt-up slab component concrete core and sheer wall construction
construction for the means of
ion with large spanning
commercial exhibiting. The system shall
comprise rth light oriented industrial ogy
Facade glazing allows lighting. As well as intricate filligree roof support
of pre-fabricated reinforced
Allows permeable surface. Overt to programme
concrete load bearing modules which
Covert to programme
are stitched together as well as into cast In-situ spanning slabs. Tilt-up slab component concrete core and sheer wall construction Facade glazing allows lighting. As well as intricate filligree roof support
The prototype system shall play off and
Allows permeable surface. Overt to programme
work with both the iconography left over from previous industrial revolutions, as well as within the existing understood typologies.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
ROBUSTNESS
A key element of this technical
requisite is the understanding of the connections between the components and ties into other types of structure, so that the proposal as a summation of parts works as an inherent structure with robustness and not merely a set of individual elements.
7
THE TYPOGRAPHIC KIT OF PARTS
The thesis looks to what a
contemporary exposition model can learn from the largely obsolesced cases that have documented previous industrial revolutions. Much of the legacy and iconography lies away from the architecture, in the efforts to create identity through the graphic approach and stylistic branding of what is foremost little more than a six month showcase. These key historic events are now perhaps more fondly referenced by the work of a typeface foundry and poster campaign rather than the fallen iconography of the architecture. The design process has largely worked with a pragmatic approach to the universal graphic setting out of typeface to inform both the macro and micro scales of the built construct. The prototype system treats pre-fabricated components as if they are characters, which are then given context within the process driven narrative of the industrial.
MINIMAL CHARACTERS MAXIMUM PERMUTATIONS
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A ProtoType Foundry Jonathan Harker A Technical Requisite
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MATERIALITY PRECEDENTS
NOTTINGHAM CONTEMPORARY Caruso St John The facade is clad in lace-patterned, precast concrete, inspired by the regular and repeated surfaces of the surrounding industrial warehouses.
HERMAN MILLER CHEROKEE OPERATIONS Mack Scogin Merrill Elam Architects
Materials include a concrete tilt-up structural wall system; steel columns, trusses, bar joints and deck at the roof; and concrete slab on grade floors.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
CASTING CONCEPT The traditional setting out of letterpress block characters within a confined tray has informed the detailed envelope aesthetic of the component system. This relieved composition of surfaces shall be demonstrated by fabricating planes of sheet cut aluminium which are the stacked and arranged to display the graphic aesthetic of a universal set of typographic guides which can generate any permutation of characters.
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SHEET WORKING ALUMINIUM The formwork for the pre-cast concrete skins will be made by configuring a set of sheet cut aluminium panels based on the typographic setting out guides. These are arranged and repeated in trays and draws directly on the concept of arranging letterpress blocks.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
Rolled Steel Sections of Window Mullions and Transoms
Toughened 12mm Double Glazed Unit
Rigid Foam core Insulation
4mm built up aluminium sheet formwork
Fly Ash Aggregate Concrete Panel Skin set with superplasticiser
Foil Insulation Casing
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TECTONIC PROCESS STORYBOARD
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A ProtoType Foundry Jonathan Harker A Technical Requisite
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40
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A ProtoType Foundry Jonathan Harker A Technical Requisite
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310
120
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PANEL TIES AND STITCHING
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19.5
Module horizontal ties are based on Anstar ASL Steel bracket locking system which is inherently tied into the Rebar structure.
290
The system effectively is comprised of
19.5
150
a bolt and socket which interlock in an
50
immovable connection which aids to achieve the level of robustness required for this type of pre-cast component sys-
39
335
20
71
tem.
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The tie drawings are dimensioned for the locking mechanism to be concealed between the two precast skins as shown
305
20
35
45
230
35
in the tectonic process storyboard.
55 100
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A ProtoType Foundry Jonathan Harker A Technical Requisite
COUPLERS AND REBAR
Couplers integrated into the panel construction will allow them to be easily lifted into place as temporary threaded inlets for lifting can be located from the reinforcement cage. These would then be craned by screwing a corresponding threaded bracket to suspend the load and manoeuvre into place.
PRECAST COMPOSITE COMPONENT SYSTEM
TECTONIC SYSTEM IN CONTEXT DETAIL 1 : 50
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SPECIFYING CONCRETE Using a concrete mix with fine Fly ash particles as an aggregate reduces the cement content whilst also giving a comparative sustainable edge over other concrete products as the fly-ash is merely a waste product of the blast furnace. The minute particles create a ball bearing effect that creates a very fluid mix when filling the formwork that rushes to the finest cavities. This also contributes to this specification of concrete being self-levelling. This would save expenditure on vibration tables and is appropriate for the over plan fine detail application within the building programme. Less water is required in the mix with the
Foundations
inclusion of a super-plasticiser. Less water equals
5000mm deep Pile foundations 850mm Concrete pile cap with extruded base plate for base component to be resin anchored and in-situ cast into position
a stronger mix that is required in load bearing instances under compression. Better
600mm Concrete ground beam
performance at resisting weathering, wind loads
250mm Compacted Core for levelling
and freeze/ thaw cycles.
Vapour barrier
Self levelling can reduce finishing time by up to 75% which would mean less labour costs.1
DETAIL SECTION
La Farge are a specialist concrete reinforcement and superplasticiser provider. Their ‘Agilia’ product uses plasticisers to reduce water content. It also imilinates the need for additional vibration. The concrete specification mix would list this super-plasticiser
ELEVATION [ NW ] 1Petricone, Pina. Concrete ideas: Material to shape a city (Thames and Hudson, London, 2012) p.22
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A ProtoType Foundry Jonathan Harker A Technical Requisite
CURING
The Pre-cast components will require 28 days of curing to attain the required strength, this is of importance due to the load bearing requirement on the vertical components. They will be cured within the industrial masonry fabrication warehouse which can be temperature controlled to the required extent. The fabrication process and factory floor can be viewed as an industrial attraction and each modular piece waiting to have a structural role can be utilised as ground level display surface and to define / break up open ‘shed’ spaces to aid wayfinding.
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EVENT APPLICATION
The nature of the casting of the envelope with a universal system for constructing typography is rooted in a commercial application during exposition events. The concrete casting will provide a physical set of guidelines to give identity to the panel during for the duration of the ‘fair’ Simple painted and transferred applications (such as 3M ScotCal Vinyl Film) will be a common interpretation however the setting out rules provide opportunity for more innovative approaches just as obscured projections or using the system to produce supergraphics at a macro scale of motif across multiple panels or whole facades.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
LEGACY ALTERATION
After the duration of the events spaces the temporary graphic painted application will be removed using one of two processes. If the removal of material required is very fine then a focused high pressure water jet can be use to take off the surface layer of paint and concrete particles. If the desired effect is to abstract the original casting and tone down the aesthetic to blend with the industrial working fabric then a grip-blasting process would be used, stripping back the material and removing the fine cast detail. This would obscure the original function but could create favourably unexpected results . It is envisaged that the legacy of such a system would employ both techniques to maintain the fine detail of the typographic casting but also mellow and wear elements of the structure into its surrounding industry.
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DETAILING THE COMPOSITION OF THE SYSTEM WORKING FROM TILT-UP SLAB PRINCIPLES With the tilt-up method concrete elements such as walls and structural supports, are formed horizontally on a concrete slab; usually the building floor, but sometimes a temporary concrete casting surface near the building footprint. After the concrete has cured, the elements are “tilted” to vertical position with a crane and braced into position until the remaining building structural components (roofs, intermediate floors and walls) are secured. Concrete elements can also be formed at factories away from the building site. Tilt-up differs from prefabrication, as all elements are constructed on the job site. This eliminates the size limitation imposed by transporting elements from a factory to the project site.1 2
1 Woodland Construction Co. 2010 2 Collins, J (2002). “Tilt-up dominates Australian construction” London Concrete Society 36 (3)
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A ProtoType Foundry Jonathan Harker A Technical Requisite
TYING BACK INTO IN-SITU SPANNING SLAB Grouted Stitching – In-situ to Pre-cast Junction Threaded Rebar protrudes 350mm and acts as a coupler which is then deformed and tied back into threaded inlets on the spanning slab reinforcement cage. Modules would be craned by screwing a corresponding threaded bracket to suspend the load and manoeuvre into place. 340mm deep In-situ cast one-way spanning slab Slab cast at junction against 120mm rigid foam insulated block slotted between modules 9.5mm diameter (No.3 grade) Reinforcing stirrups tie Rebar grid Vapour Barrier 70mm of screed and under floor heating and cooling system. Polished internal finish
FOUNDATIONS Contiguous driven pile foundations to a depth of 5000mm are required for three storey applications of the component system in this location due to the close proximity of the adjacent Grand Union Canal and geological uncertainties. 5000mm deep Pile foundations 850mm Concrete pile cap with extruded base plate for base component to be resin anchored and In-situ cast into position 600mm Concrete ground beam 250mm Compacted Core for levelling Vapour barrier Ground Beams tie back the forces (rotary moment) received at the special instance tilted corner panels from the pile caps.
1 : 20 27
SPANNING AND SIZING MEMBERS
The design allows for a maximum oneway span of 10200mm in the spanning In-situ concrete slab. The required depth for this maximum span has therefore been calculated and specified at 340mm. Length / 30 based on a one end continuous end condition of slab with an intermediate grade of reinforcement (No. 3 19mm or 40 ksi tensile stress capacity)1 10200 / 30 = 340mm Post tensioning in the spanning slabs also allows for minimising the amount of reinforcement required.
INTEGRATED LIGHTING The pre-cast modular panel design allows for 200mm at the top edge of each panel to recess floodlighting in order to illuminate the base line of typographic detail on the above panel. The lights are housed within a turn and tiltable casing, with steel sheet metal protection with a powder coated finish. The recessing allows a reflective plate to be flush with the base of the cavity anchoring out to reflect light above. The plate is mirrored on the inward facet and finished with dark grey 3M Scotch Cal vinyl acrylic transfer on the facade face.
1 : 20 1 Ambrose and Tripeny, Building Structures: Third Edition (Wiley, New Jersey, 2012) p.222 Material in Building Code Requirements for Structural Concrete (AC1 318-08)
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A ProtoType Foundry Jonathan Harker A Technical Requisite
ROOFING AND PARAPET INSTANCES
In instances where the composition of the highest storey modules are not capped within standing modules to add aesthetic roofscaping they are subtly finished and protected with the small parapet. The material detailing of these roofing slab to parapet junctions is listed below are demonstrated opposite; 2mm aluminium flashing Duplex Board with vapour barrier Silicon seal with compressible filler 60mm Insulation Wooden batten to seal cavity 50mm Thermabate cavity closer on roof facing edge Ties to Concrete Up-stand butted against In-situ cast spanning slab Vapour Barrier
1 : 10 29
DIFFICULTIES IN SITE SPECIFIC IMPLEMENTATION
Due to the proximity of the adjacent historic Duddleston viaduct to the built works several key technical processes must employed. A specialist compact pile driver will be required to get to within 1500mm of exisitng masonry structures. So not to disturb their groundworks, in a few instances the pile caps and cast ground beams will required a cantilever in order to achieve sitting the precast components close against existing masonry construction. The post tensioning in the In-situ cast spanning slab will have to in some instances be applied from a dead anchorage point in one direction due to restricted access.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
COMPOSITE PRE-CAST MODULE Outer Skin – 100mm Concrete panel pre-cast against built - up sheet cut aluminium sections in 4mm intervals Concrete reinforced with 19mm diameter (No.6 grade) Reinforcement bars spaced at 300mm intervals Damp Proof Membrane (Damp proof course running horizontally where In-situ slab meets pre-cast panels and rigid insulating block) 120mm Rockwool fibrous insulation in cavity between concrete skins
UValue Calculator 19mm Rebar ties and spaces concrete
Thermal transmittance (Uvalue) according to BS EN ISO 6946 2007
Project
skins
Inner Skin – 100mm reinforced Concrete pre-cast panel (cast smooth or with relieved system as internal finish)
Reference
Modules are horizontally tied by Anstar
ASL Steel bracket locking system which Building Type is inherently tied into the Rebar structure
External Wall
Element Type: Perimeter (m):
Area (m2):
Max UValue U = 1/RT = 0.28 W/m2K
GENERATING THE U-VALUE OF A MODULAR PRECAST COMPONENT P/A = N/A
Thermal Cond. (W/m2K)
Material
%
Thickness (mm)
Resistance (m2K/W)
Internal Surface ( Rsi )
0.1300
Reinforced concrete 2% steel Glass fibre/Wool batt Reinforced concrete 2% steel
2.50 0.035 2.50
100 100 100
External Surface ( Rse )
Total thickness: Total resistance: UValue (uncorrected): Total ΔU: UValue (corrected):
100 120 100
0.0400 3.4286 0.0400
0.0400
mm
RT = Rsi+R+Rse =
320.0 3.679
U = 1/RT =
0.272
W/m2K
0.272
W/m2K
m2K/W
0.000 U = 1/RT+ ΔU =
31
Disclaimer: Please be aware that you use this U Value calculator entirely at your own risk. No responsibility for the accuracy of this data or any outcome due its use is accepted by ChangePlan Ltd or any of the parties involved in creating or
VENTILATION STRATEGY The ventilation strategy for the building
Ventilation Rate
will be a hybrid solution calling on both natural and mechanical ventilation.
The ventilation air change rate for theatres and exhibition spaces is given in
Due to the programme of
the CIBSE guide Table B2.3 as 6-10 air
public spaces taking large visiting
changes per hour.
capacity crowds ventilation
This is total air supply rate.
rate and
changing the circulating air is of integral importance to the successful operating
The amount of fresh air supplied per oc-
and comfort of the environment.
cupant is specified in Table B2.2 as
8 litres per second per person for
Large rooms such as lecture
rooms; theatres, conference rooms,
non-smoking areas. These two figures
exhibition halls, auditoria and halls for
can determine the air flow rates in the
public gatherings need careful designing
ventilation system.
for ventilation or air conditioning. Two of the most important design criteria
Ventilation rate (m3/h)
=
are:
Air Change Rate (/h)
x
- The ventilation rate.
Room Volume (m3)
- The distribution of air in the space.
MECHANICAL
HYBRID
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A ProtoType Foundry Jonathan Harker A Technical Requisite
USING CORES FOR STACK EFFECT VENTILATION
The naturally ventilated concrete cores are capped with a permeable composition of layered glazing and CNC cut aluminium profiles which provide a breathable roofing skin. Warm arm convects through the ground floor from the entrances
and
apertures
and
rises
through the channelled core. It dissipates and convects out from the core openings on each floor before passing through the natural roofing ventilation. The convection imbalance in pressure then draws cool air in again at the base of the design and the buoyancy of heating the rising air is repeated in the ‘stack effect’.
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FIRE STRATEGY
[ 1 ] Means of escape and alarming [ 2 ] Inhibiting the spread of fire across the internal linings [ 3 ] Adequate fire resistance of the structure to maintain stability and compartmentalisation [ 4 ] Prevention of fire spread between buildings [ 5 ] Adequate provision for Fire service access up to a through buildings; fire fighting facilities.
- GROUND FLOOR 25m
Maximum travel distance to closest
exit from two emergency egress strategies
25m
23m
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A ProtoType Foundry Jonathan Harker A Technical Requisite
- 1st FLOOR -
14m
Maximum travel distance to closest
exit from two emergency egress strategies
14m
11m
- 2nd FLOOR -
15m
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Maximum travel distance
HEATING AND COOLING
Some areas of the programme will have the requirement to have underfloor cooling as well as heating due to the nature of their inhabitation. For example the Printworks production floor will have heavy machinery running for extensive periods of time, massively contributing to the internal gains. This paired with the large crowds of visitors concentrated with a potentially uneven distribution,
UNDERFLOOR HEATING
demonstrate why a dual system such as those offered by companies such as
Timoleon of underfloor heating and cooling would be favourable for this project.
UNDERFLOOR COOLING
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Practice Management and Economics MArch 2
A ProtoType Foundry Jonathan Harker A Technical Requisite
Economics Oral Examination
ECONOMICS PROFORMA
Executive Summary Your Name:
Jonathan Harker
Studio:
Economy
Principal Building Function (s)
Exhibition Spaces, Printworks and Fabrication in sheet metalworking and precast concrete components
Site Location
Digbeth, Birmingham
Promoter/Client:
Recognised as a specialist exposition by the BIE (Bureau International des Expositions). Must have a precise character to its theme. One of two forms of acknowledgement, rather than a registered event (also known as a World Expo) Commercial Promoter - Google ‘Exhibit’ or similar online platform promoting letting of commercial units through a recognised exposition. Business Birmingham, Millennium Point, Birmingham City University Google ‘Exhibit’
Principal Funding Sources
Payback through commercially lettable modular units through online platform and trade in prefrabricated building systems. A secondary level structure of corporate sponsorship
Brief statement of how scheme represents value for the promoter
The appraisal of the EXPO model utilises existing industrial character, iconography and warehouse typology spaces rather than new vast capital investments. Transport Infrastructure links will be in place due to the close proximity to HS2 hub at Curzon Street. The scheme is proposing the pioneering of a prototype exhibiting system, which can generate revenue when used within other urban conditions and events. The scheme aims to give architectural manifestation to an online platform promoter requiring easily replicable identity within the built environment.
Proposed Gross Internal Floor Area
Net to gross ratio:
(New Build) 4950m2
(New Build) 1 : 1.22
Estimated Costs (State sources) The source of estimated costing is SPON’S Architect’s and Builder’s Price Book 2012 unless stated. Zone/Function
Approx £m
Exhibition Centres
2
2
Area (m )
Total (£)
1300
4950
6,435,000
Excavation and disposal off site
22
1877
41,294
Specialist excavation and machinery for use amongst existing structure
52
400
20,800
Fully Piled Foundations in poor ground (adjacent to Grand
230
1877
431,710
(SPONS Guide Estimation per 2 m building type) Preparatory works and Substructure
37
Union Canal) Ground Beams
(Linear Metre) 140
(Linear Metre) 243
34,020
Demolition
62
410
25,420 700,000
Restoration (Based on Restoration works to Accrington Viaduct, March 2013)
Superstructure (by precedent) Precast Concrete Panel Structure and envelope construction
540
4950
(Generated from precedent conversion from $ and taking into account inflation since 2000)
(Based on Herman Miller Cherokee Plant, Tilt up Concrete Slab Construction Precedent)
Roofing
2,673,000
94
1250
117,500
75mm thick lightweight screed roof covering and vapour barrier
18
1250
22,500
Existing Fabrication Warehouse Roof Replacement
35
3900 (Flattened Pitch)
136,500
Existing Printworks Warehouse Roof Replacement
37
2430 (Flattened Pitch)
89,910
Roofscaping and Landscaping
(29 + 40) 69
2015
139,000
Industrial Printworks category A fit out (developers)
450
373
167,850
Industrial Printworks category A fit out (tenants)
300
373
111,900
Component Fabrication Warehouse category A fitout
475
1025
487,000
245
(75 x 16) 1200
294,000
53,000 (total)
x3
106,000
44,360 (total)
x2
88,720
Concrete Flat Roofing Reinforced Spanning Slab (no coverings or finishes)
(Generated from online quote calculator for project spec from Accord steel cladding)
Interior Finish and Fit out
Flexible Exhibition System Fit out Modular Exhibition System (Based on POD Exhibition systems – Arena 4 Kit E) Lift Shafts Glazed shaft 3 x 6 person carriage. 2 x Heavy industrial goods lift.
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A ProtoType Foundry Jonathan Harker A Technical Requisite
Fire Strategy
8
4950
39,600
Sprinkler system
15
145 + 1296
21,615
(Metal casting foundry and Print house production floor)
(SPONS Mechanical and Electrical 2011)
Mechanical Ventilation
200
1441
288,200
Toilets and Sanitation
52
160
8,320
Interior Artificial Lighting
18
4950
89,100
Underfloor Heating and Cooling
30
5323
159,690
Smoke detection
AC and extraction in industrial process spaces. Heat recovery due to air change requirements
Total Estimated Cost:
6,293,649
Estimated Superstructure Costs by Modular Component Type of Component
Approx ÂŁ per component
Number of Instances
Standard Component
Fine aggregate highly specified concrete mix with polypropylene fibrous additive and super-plasticiser.
Component Modular design
116 per m
3
53,424
144
131,328
3
3.2m per component 371
2
912 (16m )
4000mm x 4000m Reinforced concrete double skin with insulation and DPM
Additional Labour and Formwork costs (Base rate)
144
848 (53 x 16)
Economy of Scale through re-use
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First 9 panels
848
9
7,632
Up to 27 Panels
645
18
11,610
Up to 180 Panels
110
117
12,870
81
37,584
81
202,500
460
9
4,140
350
18
6,300
60
54
3,240
140
144
20,160
Special Component
Fine aggregate highly specified concrete mix with polypropylene fibrous additive and super-plasticiser.
Special Component used in vertex instance. Requires curvature in formwork and sloping up to 15 degrees
Additional Labour and Formwork costs (Base rate)
116 per m
3
3
4m per component 464
2
2500 (20m )
460 (23 x 20)
Economy of Scale through re-use First 9 panels Up to 27 Panels Up to 90 Panels
Exterior Component Floodlighting (Standard Panels)
Total Estimated Cost for Modular Vertical Components: Element
Approx £m
In-Situ One-way PostTensioned spanning slab Formwork –Galvanised steel support struts and shuttering
2
2
490,788
Area (m )
Total (£)
107
4950
529,650
33
4950
163,350
Total Estimated Cost for In-situ cast Spanning Slabs: Total Estimated Cost for Concrete Superstructure based on Modular Components:
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693,000 1,183,788
A ProtoType Foundry Jonathan Harker A Technical Requisite
EXHI BI T
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Costly Elements
Cheap Elements
Fabrication of the CNC sheet cut aluminium formwork
Reproduction of modular building system and ability to achieve an economy of scale.
Site Specific construction, specialist processes and machinery required eg. Smaller scale pile driver and one way post tensioning due to proximity to existing structures. Crane hire and access points
Uniform material finishes with few additives. Reuse of formwork. Specified concrete is self levelling and can save on costs for labour, vibration tables etc. Creation of image value
Complex joints and connecting systems between components, however they are uniform and so achieve an economy of scale.
Revenue Earning Capacity
Significant Operating/Lifecycle costs
Envelope Skin sold for event duration as commercially lettable area. Commercial draw and image value of being part of an architectural prototype system is as valuable as the occupation of 2 multiples of 16m envelope area.
Concrete structure can entail significant maintenance costs after first 20 years such as cracking, shrinkage and expansion through freeze thaw cycles.
Exposition gains turnover from taking an exhibitors fee from the product sales made by companies.
Spaces will be rented out to the specific smaller industries; metal casting foundry, graphic design and typeface foundry and printworks.
Process to allocate legacy use to exhibition spaces. Potentially high overheads that will need to be taken on by a long-term tenant. Idea is that the architectural identity becomes the language of the online platform promoter who adopt the EXPO space as their operations centre whilst valuing and supporting the industry and ‘making’ aspects of the programme, metal casting foundry, print house, fabrication and typeface foundry.
The industrial landscape chosen at the centre of Digbeth works at a model urban, left-over industrial fabric for which this prototype system can be applied and sold elsewhere.
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